Installation Instructions Capacity 10,000 lbs. DP10 (200 Series Lift)

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1 Installation Instructions Capacity 10,000 lbs. DP10 (200 Series Lift) IMPORTANT Reference ANSI/ALI ALIS, Safety Requirements for Installation and Service of Automotive Lifts before installing lift. OPERATING CONDITIONS Lift is not intended for outdoor use and has an operating ambient temperature range of F (5-40 C) LP60025 May 2015 by Vehicle Service Group. All rights reserved. CO9345 IN60025 Rev. D 5/11/2015

2 F G H E I A B C Fig. 1a 23" MIN ARM REACH 44 1/2" MAX ARM REACH J K Fig. 1b L 38 1/2" MIN ARM REACH 58"MAX ARM REACH L 2

3 1. Lift Location: Use architects plan when available to locate lift. Fig. 1a & Fig. 1b shows dimensions of a typical bay layout. WARNING DO NOT install this lift in a pit or depression due to fire or explosion risks. A POWER UNIT HEIGHT 72 1/2" B LIFTING HEIGHT W/ 5" EXTENSION 76 1/8" W/ 67 1/2" STROKE LIFTING HEIGHT W/ HIGH RISE CYLINDER 79 5/8" W/ 71" STROKE C MIN. LIFT HEIGHT 3 5/8" MIN. LIFT HEIGHT W/ 1 3/4" ADAPTER MIN. LIFT HEIGHT W/ 3 1/2" ADAPTER MIN. LIFT HEIGHT W/ 5" ADAPTER 5 3/8" 7 1/8" D OVERALL FLOOR WIDTH 136 1/2" OVERALL FLOOR WIDTH (NARROW) 130 1/2" E WIDTH BETWEEN CARRIAGES 112 1/2" WIDTH BETWEEN CARRIAGES (NARROW) 106 1/2" F INSIDE COLUMNS 114 1/2" INSIDE COLUMNS (NARROW) 108 1/2" G HEIGHT OVERALL (HOSE NOT INCLUDED) 143 1/2" EXTENDED HEIGHT OVERALL (HOSE NOT INCLUDED) 166 1/2" MINIMUM CEILING HEIGHT 144" MINIMUM CEILING HEIGHT (EXTENDED HEIGHT) 167" H FLOOR TO OVERHEAD SWITCH 137 3/4 I DRIVE THRU CLEARANCE 104 1/2" DRIVE THRU CLEARANCE (NARROW) 98 1/2" J MINIMUM TO NEAREST OBSTRUCTION 132" K MINIMUM TO NEAREST OBSTRUCTION 156" L MINIMUM TO NEAREST OBSTRUCTION 72" NOTES: 1.) ALL HEIGHT DIMENSIONS ARE WITHOUT LEVELING SHIMS. 2.) STANDARD HEIGHT LIFT SHOWN. 3.) ** ANCHORING SYSTEM TESTED TO ANSI/ALI ALCTV:2006 LIFT CAPACITY 10,000 LBS. LIFTING SPEED (RISE TIME) APPROXIMATELY 45 SECONDS UNLOADED APPROXIMATELY 51 SECONDS AT RATED CAPACITY 3 PHASE /460V Hz 17/8.5-14/8 AMPS MOTOR RATING OPTIONS SINGLE PHASE V 60Hz 16 AMPS SINGLE PHASE V 50Hz 15 AMPS WEIGHT 1505 LBS MECHANICAL SAFETY LOCKS AUTOMATIC ALL POSITIONS MECHANICAL SAFETY RELEASE MANUAL ALL BOTH COLUMNS SWING ARM RESTRAINTS AUTOMATIC ENGAGEMENT ABOVE 2 1/2" HYDRAULIC SAFETY SYSTEM AUTOMATIC ALL POSITIONS CYLINDERS TWO, ONE PER COLUMN CARRIAGE BEARINGS EIGHT PER CARRIAGE, UHMW SYNCHRONIZATION EQUALIZATION CABLES MIN. BAY SIZE 12' X 24' VERIFY WITH SITE PLAN & SERVICE VEHICLES 8 5/8" FLOOR TO OVERHEAD SWITCH (HIGH RISE) 160 3/4 3

4 2. Latch Cable Guides: Install the latch cable conduit guide brackets to column using (1) 1/4-20NC x 1 HHCS and 1/4-20NC Flanged Locknut. It should go through hole nearest the edge as shown, Fig. 2. For extension please note paragraph Column Extension (Extended Height): Column extension is installed using (2) M10-1.5x20mm HHCS & (2) M Flg. Lock Nut on the inside of the lift column. Use (2) 1/2-13x1-3/4 HHCS, (4) 1/2 Flat Wahser, and (2) 1/2-13 Nylon Locknut on the outside of the column, Fig. 4. After the extension is installed install the latch cable guide on the outside of extension using (1) 1/4-20NC x 1 HHCS and 1/4-20NC Flanged Locknut, Fig. 4. Attach tie bar to column with (2) 1/2-13x1-3/4 HHCS, (2) 1/2 Flat Washer, and (2) 1/2-13 Nylon Locknut, Fig. 4. Fig. 2 Fig. 4 1/2-13x1-3/4 HHCS & 1/2 Flat Washer Note: Standard height installation continue to paragraph 6. For extended height continue to paragraph Male Connector (Extended Height): Attach male connectors to tops of cylinders before installing the extended height column extensions see Fig. 3. M10-1.5x20mm HHCS & M Flg. Locknut 1/2-13 Nylon Locknut & 1/2 Flat Washer 1/2-13 Nylon Locknut & 1/2 Flat Washer 1/2-13x1-3/4 HHCS Fig. 3 3/8 NPT to 1/4 Tube Male Connector 4

5 5. Cylinder Install (Extended Height): With the extension installed the cylinder will be installed with (1) 1/2-13x4-1/2 HHCS, (2) 1/2 Flat Washer, (2) 1/2 Cylinder Spacer, and (1) 1/2-13 Nylon Locknut, Fig. 5. The lift carriage should now be manually raised to the bottom of the cylinder. The cylinder is then attached to the carriage using (1) 3/4-16 Hex Nut and (1) 3/4-16 Hex Jam Nut, Fig. 5. Fig. 5 1/2-13NC x 4-1/2 HHCS, 1/2 Flat Washer, &Cylinder Spacer Place cylinder in this hole when using T Extended Height Kit only 1/2-13NC Nylon Locknut, 1/2 Flat Washer, & Cylinder Spacer Place cylinder in this hole when using Extended Height High Rise Lift 3/4-16 Hex Nut 3/4-16 Hex Jam Nut 5

6 Use for narrow bay setting. 90 Elbow Fig. 6 Remove Plug Standard Cable Tie Off & 5/8" Nylon Insert Locknut 6. Cylinder Fitting: Prior to standing up lift columns, install the 90 elbow fitting to the cylinder and equalizer cable to the bottom of the carriage Fig 6. Remove plug from the top of the cylinders and install the appropriate fittings per Fig. 15a CAUTION Over tightening will damage fitting resulting in fluid leakage. 7. Equalizer Cables A.) First, run a cable end up through the small hole in the standard tie-off plate. Fig. 6. B) Push the cable up until the stud is out of the carriage top opening. C) Run a nylon insert locknut onto the cable stud so 1/2 (13mm) of the stud extends out of the locknut. D) Pull the cable back down, Fig. 6. E) Run cable around the lower sheave, then up and out of the top of the column. 8. Lift Setting: Position columns in bay using dimensions shown in Fig. 1a & Fig. 1b. Place column with power unit mounting bracket on vehicle passenger side of lift. Both column base plate backs must be square on center line of lift. Notches are cut into each base plate to indicate center line of lift. Use appropriate equipment to raise carriage to first latch position. Be sure locking latch is securely engaged. 9. Concrete and Anchoring: Drill (10) 3/4 dia. holes in concrete floor using holes in column base plate as a guide. See Fig. 8 for hole depth, hole spacing, and edge distance requirements. Fig. 7 Shims (1/2" Max.) 6 CAUTION DO NOT install on asphalt or other similar unstable surfaces. Columns are supported only by anchors in floor. IMPORTANT Using the horse shoe shims provided, shim each column base until each column is plumb. If one column has to be elevated to match the plane of the other column, full size base shim plates should be used (Reference FA9116 Shim Kit). Recheck columns for plumb. Tighten anchor bolts to an installation torque of 110 ft-lbs. Shim thickness MUST NOT exceed 1/2 when using the 5-1/2 long anchors provided with the lift, Fig. 7. Adjust the column extensions plumb. If anchors do not tighten to 110 ft-lbs. installation torque, replace concrete under each column base with a 4 x 4 x 6 thick 3000 PSI minimum concrete pad keyed under and flush with the top of existing floor. Let concrete cure before installing lifts and anchors. Anchor Nut Flat Washer NOTE: Use rectangular shims at inside edge of baseplate. Use constructions adhesive or silicon cement to hold shim in place. INSURE shims are held tightly between base plate and floor after torquing anchors. NOTE: If more than 2 horse shoe shims are used at any of the column anchor bolts, pack non-shrink grout under the unsupported area of the column base. Insure shims are held tightly between the baseplate and floor after torquing anchors.

7 Fig. 8 Drill holes using 3/4 carbide tipped masonry drill bit per ANSI B (R2000) Clean hole. Run nut down just below impact section of bolt. Drive anchor into hole until nut and washer contact base. CONCRETE AND ANCHORING REQUIREMENTS Tighten nut with Torque wrench to 110 ft.-lbs. STANDARD ANSI/ALI ALCTV IBC 2006, 2009, 2012 SEISMIC Minimum Floor Thickness Anchor Minimum Concrete Strength Minimum Anchor Embedment Minimum Distance to Concrete Edge, Crack, Expansion Joint, Abandanoned Anchor Hole 4-1/4 INCHES 4-3/4 INCHES Extended Height Lift or Kit Hilti Kwik Bolt III 3/4" x 5-1/2" Anchors supplied with the lift.* Hilti Kwik Bolt III 3/4 x 7 Extended Height Anchors supplied with the Lift or kit.* 5 INCHES 6 INCHES Varies by location consult with your structural engineer and manufacturer s representative. Hilti HIT-HY 150 MAX-SD Adhesive; Hilti HIT-HY 150 MAX Adhesive; HILTI HIT-RE 500- SD Adhesive Hilti Kwik Bolt III 3/4" x 7" 3000 PSI 3000 PSI 3000 PSI 3-1/4 INCHES 3-5/8* Extended Height Lift or Kit 3-1/2 INCHES 3-3/4 INCHES 4-1/2 INCHES 5-1/4 INCHES 3-1/4 INCHES 3-3/4* Extended Height Lift or Kit *The supplied concrete fasteners meet the criteria of the American National Standard Automotive Lifts - Safety Requirements for Construction, Testing, and Validation ANSI/ALI ALCTV-2011, and the lift owner is responsible for all charges related to any additional anchoring requirements as specified by local codes. Contact customer service for further information at:

8 10a. Overhead Assembly: Fig. 10: Adjust overhead to appropriate dimension. Install (4) M x 20mm HHCS & M Flanged Locknuts, do not tighten. Slide Switch Box Fig. 9 over switch bar ensuring knock out holes face the power unit column. Use (2) 1/4-20NC x 3/4 lg. HHCS, 1/4 Flat Washer, and 1/4-20NC Nuts to mount switch box to overhead, see Fig b. Continued Overhead Assembly: For single phase lifts: Insert 1/4-20NC x 2 3/4 HHCS through pivot hole in end of switch bar. Insert opposite end of bar through slot in switch mounting bracket. Then secure HHCS and Switch Bar to overhead as shown, Fig. 10, using (2) 3/4 spacers and 1/4-20NC Locknut. Tighten Hex bolt leaving 1/16 gap between the spacer and the overhead assembly. Fig. 9 M x 20mm HHCS & Flanged Locknut 11 3/4" Standard 7 3/4 Narrow 114" Standard 108 Narrow Bay Fig. 10 Open Bar Side Hardware Detail For Overhead Assembly Switch Box Side 1/4" Lock Nut 1/4" Lock Nut 2 Spacers 1/4" Flat Washer 1/4"-20NC x 2 3/4" HHCS HOLE DETAIL 1/4"-20NC x 3/4" HHCS Standard Bay Narrow Bay 8

9 For three phase lifts: Remove Limit Switch cover, Fig. 11. Insert Actuator end of Switch Bar into slot located inside Limit Switch, Fig. 11. A small amount of silicone sealant on the lower part of the actuator will help hold it in place. Insert 1/4-20NC x 2 3/4 HHCS through pivot hole in end of Switch Bar. Then secure HHCS and Switch Bar to overhead as shown, using (2) 3/4 spacers and 1/4-20NC Locknut. Tighten Hex bolt leaving 1/16 gap between the spacer and the overhead assembly, Fig. 10. Replace limit switch cover. Use M x 20mm HHCS and Locknuts Fig. 12 Fig. 11 Place Actuator Here. A Small Amount Of Silicone Sealant On The Lower Part Of The Actuator Will Help Hold It In Place. Actuator Remove Screws And Cover Cradle Bar On Actuator 12. Power Unit: First install a star washer onto all of the (4) 5/16-18NC x 1-1/2 HHCS. This is very important for grounding. Put the (4) 5/16-18NC x 1-1/2 HHCS thru holes in power unit bracket, Fig. 13. Mount unit with motor up to column bracket and install (4) 5/16 star washers and 5/16 Nuts. Install and hand tighten fitting to pump until O-ring is seated. Continue to tighten the locknut until the nut and washer bottom out against the pump manifold. NOTE: You may still be able to rotate the fitting. This is acceptable unless there is seepage at the O-ring. If so, slightly tighten the locknut. CAUTION Over tightening locknut may tear O-ring or distort threads in pump manifold outlet. 13. Hoses: Clean adapters and hose. Inspect all threads for damage and hose ends to be sure they are crimped, Fig. 14. Install hose and hose clamps, Fig. 15a, Fig. 15b, Fig. 15c, & Fig. 19a. Flared Fittings Tightening Procedure 1. Screw the fittings together finger tight. Then, using the proper size wrench, rotate the fitting 2-1/2 hex flats. 11. Overhead Installation: Install overhead assembly to Mounting Bracket with (4) M x 20mm HHCS, and (4) M Flanged Locknut on both columns Fig. 12. Tighten bolts at center of overhead assembly. IMPORTANT Flare seat MUST NOT rotate when tightening. Only the nut should turn. 2. Back the fitting off one full turn. 3. Again tighten the fittings finger tight; then using a wrench, rotate the fitting 2-1/2 hex flats. This will complete the tightening procedure and develop a pressure tight seal. 9 CAUTION Over tightening will damage fitting resulting in fluid leakage.

10 Use (4 5/16"-18NC x1-1/2" lg. HHCS and Nuts On all four bolts, place (2) 5/16" Star Washers Fig. 13 Fig. 11 Fill Breather Cap 4. Place the assembled T fitting behind the cylinder and connect the hoses to the two cylinder ends and the Power Unit. 5. Take up the slack in the Power Unit side cylinder hose and wire tie the T fitting tightly to the power unit side cylinder. 6. Secure each hose as needed. 7. Run return line from elbow Pc. (8) to tee Pc. (9). The return line then runs outside of column down and connects to the power unit, Fig. 15a. NOTE: Overhead hose goes over top end of overhead assembly, Fig. 15a, Fig. 15c, Fig. 19a, & Fig. 19b Overhead Hose Return Line 7 6 Hose runs down approach side to cylinder on left column. Fitting Wire ties secure hose to cylinder. 3 Fig. 14 Fitting 5 Adapter & Hose Installation (Standard Height) 1. Before installing the hoses into the lift, attach the Overhead hose Pc. (3) and Cylinder hose Pc. (4) to the T fitting Pc. (6) as shown in Figure 15c. 2. Route the assembled hose through the overhead but do not attach to either cylinder. 3. Route the Power Unit hose Pc. (5) through the column hole and attach it to the T fitting. IMPORTANT : Before you connect the power unit hose you must tuck the hoses and union tee behind the cylinder to give you room to complete installation, Fig 15c FRONT Fig. 15a ITEM QTY. DESCRIPTION 1 1 Power Unit Side Cylinder 2 1 Slave Side Cylinder 3 1 Overhead Hose 4 1 Cylinder Hose 5 1 Power Unit Hose 6 1 3/8 Branch Tee 7 1 Return Line 8 1 1/4 Elbow 9 1 1/4 Branch Tee 10 2 Hose Clamps 2 M x 20mm HHCS 2 M Flanged Locknuts 2

11 Adapter & Hose Installation (Extended Height) 1. Before installing the hoses into the lift, attach the Overhead hose Pc. (3) and Cylinder hose Pc. (4) to the T fitting Pc. (6) as shown in Figure 15c Route the assembled hose through the overhead but do not attach to either cylinder. 3. Route the Power Unit hose Pc. (5) through the column hole and attach it to the T fitting. 6 5 Hose runs down approach side to cylinder on left column. IMPORTANT : Before you connect the power unit hose you must tuck the hoses and union tee behind the cylinder to give you room to complete installation, Fig 15c. Wire ties secure hose to cylinder Place the assembled T fitting behind the cylinder and connect the hoses to the two cylinder ends and the Power Unit Take up the slack in the Power Unit side cylinder hose and wire tie the T fitting tightly to the power unit side cylinder. 6. Secure each hose as needed. 7. Run return line from Pc. (8) to tee Pc. (9) on both cylinders. The return line then runs outside of column down and connects to the power unit, Fig. 15b. 2 1 FRONT Fig. 15b NOTE: Overhead hose goes over top end of overhead assembly, Fig. 15b, Fig. 15c, Fig. 19a, & Fig. 19b. ITEM QTY. DESCRIPTION 1 1 Power Unit Side Cylinder 2 1 Slave Side Cylinder 3 1 Overhead Hose 4 1 Cylinder Hose 5 1 Power Unit Hose 6 1 3/8 Branch Tee 7 1 Return Line 8 2 3/8 to 1/4 Male Connector 9 1 1/4 Branch Tee 10 2 Hose Clamps 2 M x 20mm HHCS 2 M Flanged Locknuts 11

12 Overhead Hydraulic Hose To Passenger Side Cylinder Assemble These 3 Items Before You Route Them Inside The Lift Assembly Overhead Hydraulic Hose To Passenger Side Cylinder Union Tee Power Unit Column Hydraulic Hose To Passenger Side Cylinder Power Unit Hydraulic Hose Union Tee Hydraulic Hose To Power Unit Side Cylinder Hydraulic Hose To Power Unit Side Cylinder Fig. 15c IMPORTANT Wire Tie Union Tee And Hydraulic hoses behind the Cylinder Power Unit Column 12

13 14. Equalizing Cables A) Refer to Fig. 17 for the general cable arrangement. B) Run cable from paragraph 7 around overhead sheave and across and down to the opposite carriage, Fig. 17. Install sheave cover, Fig. 16. C) Fasten the cable end to the carriage upper tie-off bracket, Fig. 18. Tighten the locknut enough to apply light tension to the cable. D) Adjust the tension of both cables during the final adjustments in Paragraph 24. Upper Cable Tie Off & 5/8" Nylon Insert Locknut Fig. 18 Narrow Cable Tie Off Fig. 16 Sheave Cover Standard Cable Tie Off Upper Sheaves 2nd Cable Fig. 17 1st Cable Lower Sheaves 13

14 15. Locking Latch Cable A) Install latch cable sheave and retainging rings in upper slot of power unit column as shown, Fig. 20. B) Slip loop end of cable over end of shoulder screw on right side latch control plate, Fig. 20. C) Feed the other end of the cable through the latch cable sheave slot making sure that the cable is running under the bottom side of the latch cable sheave and inside the right column, Fig. 20. D) Attach latch cable conduit guide brackets to overhead as shown, Fig. 19a & Fig. 19b. Always use the holes on the approach side of the lift. HHCS should be in hole nearest the center of the overhead, Fig. 19b. E) Route cable up inside column and through the latch cable guide, Fig. 19a & Fig. 21. IMPORTANT Using wire ties provided, tie off hydraulic hose snug to cylinders to keep hose away from equalizing cable, Fig. 15a. F) Continue routing cable to the left column latch cable guide, Fig. 19a & Fig. 21, routing the cable through the left column latch cable guide, Fig. 19a. G) Bring the cable down inside the left column and feed the end of the cable through the lower latch cable sheave slot so that the cable is now back outside the column, Fig. 22. H) Route cable under the bottom side of the latch cable sheave, Fig. 22. I) At this point you MUST install the latch handle, jam nut, and right column latch cover Fig. 20 & Fig. 23. Install latch handle ball, Fig. 23. J) Insert cable in cable clamp along one side, loop around shoulder screw and back down, inserting cable along other side of cable clamp, Fig. 22. Place top back on clamp, barely tightening. K) Next, pull the control plate down, Fig. 21 & Fig. 22, to eliminate any clearance between the control plate slot and the latch dog pin, Fig. 21. L) Using Pliers, pull cable tight and secure the clamp close to the shoulder screw. Tighten clamp. Cable Guide runs UNDER hydraulic hose M x 20mm HHCS and Flanged Locknut M x 20mm HHCS and Flanged Locknut Cable Guide does not cross hydraulic hose Fig. 19a 1/4"-20NC x 1" HHCS and Flanged Locknut 1/4"-20NC x 1" HHCS and Flanged Locknut Attach Hose Clamps Here Attach Latch Cable Conduit Guide Bracket Here. Always use two holes on approach side of extension to attach bracket. Always put HHCS through hole closest to center of overhead. APPROACH Fig. 19b 14

15 Latch Cable Sheave (2) 3/8" Retaining Rings Fig. 20 Shoulder Bolt Install Latch Handle using a 3/8" hex jam nut to lock in place. Then install flat washers and slot cover. Latch Cable Latch Cable Guide Fig. 21 (3) 3/8 Flat Washers Notice the clearance removed between Control Plate Slot and Latch Dog Pin. Slot Cover Shoulder Bolt Right Column Feed cable up through Cable Clamp, loop over end of shoulder bolt and feed back down through Cable Clamp. Cable Clamp Latch Cable Sheave Fig. 22 (2) 3/8" Retaining Rings 5/16-18NC x 3/8" lg. PHMS Latch handle MUST be positioned at the top of the latch control cover. Fig Ball Handle

16 16. Electrical: Have a certified electrician run appropriate power supply to motor, Fig. 24 & 25. Size wire for 20 amp circuit. See Motor Operating Data Table. CAUTION Never operate the motor on line voltage less than 208V. Motor damage may occur. Single Phase Power Unit MOTOR OPERATING DATA TABLE - SINGLE PHASE LINE VOLTAGE RUNNING MOTOR VOLTAGE RANGE V 50Hz V V 60Hz V IMPORTANT: Use separate circuit for each power unit. Protect each circuit with time delay fuse or circuit breaker. For single phase V, use 20 amp fuse. Three phase V, use 20 amp fuse. For three phase 400V and above, use 10 amp fuse. For three phase 380V use 16 amp fuse. For wiring see Fig. 24 & Fig. 25. All wiring must comply with NEC and all local electrical codes. 230V 60Hz 1 Ø Black Green White Disconnect (If Required) Overhead Limit Switch Black Up Switch Black White M NOTE: Assure cord used for connection between the overhead switch and power unit is of the type specified in: UL201, Sections & White Black Green V 60Hz Single Phase Fig. 24 Size for 25 amp circuit. See UL 201, Section 15 for proper wiring requirements for this connection. Attach black wire to one motor wire. Attach white wire to one motor wire. Overhead Switch Max. Voltage: 277V Max. Current: 25A Attach ground wire here. Connect supply to wires in box as per Fig. 20. Attach ground wire to screws provided. 16

17 3 Phase Gasket Drum Switch And Cover Re-seal Between Box And Spacer With Silicone Sealer Capacitor Box (4) M5 x 45 PHMS, Plated 3 Phase Supply L1 L2 L3 PE MOTOR (4) M5 x 10 PHMS, Plated Capacitor Box To Power Unit OVERHEAD SWITCH (WHERE APPLICABLE) DRUM SWITCH Fig. 25 Three Phase Power Unit MOTOR OPERATING DATA TABLE - THREE PHASE LINE VOLTAGE RUNNING MOTOR VOLTAGE RANGE V 50/60Hz V 400V 50Hz V V 50/60Hz. 396V-528V 575V 60Hz. 518V-632V L3 L2 L1 T3 T2 T1 T9 T8 T V 50/60Hz. 3Ø T6 T5 T4 L3 L2 L1 T3 T2 T1 T9 T8 T7 T6 T5 T V 50/60 Hz. 3Ø V 50 Hz. 3Ø V2 W1 U2 V1 W2 U1 575V 60 Hz. 3Ø T3 T2 T1 17

18 17. Oil Filling & Bleeding: Use Dexron III ATF, or Hydraulic Fluid that meets ISO 32 specifications. Remove fill-breather cap, Fig. 13. Pour in (8) quarts of fluid. Start unit, raise lift to full rise several times until lift operates smoothly. CAUTION If fill-breather cap is lost or broken, order replacement. Reservoir must be vented. 18. Overhead switch: Check overhead switch assembly to assure that switch bar is depressing switch plunger sufficiently to actuate the switch. The overhead switch is wired normally open, see Fig. 24 & Fig. 25. Lift will not operate until weight of switch bar is depressing switch plunger. Verify that Power Unit stops working when switch bar is raised, and restarts when the bar is released. 19. Arms & Restraints: Before installing arms, raise carriages to a convenient height. Grease swivel arm pins and holes with Lithium grease. Slide arm into yoke, Fig. 26a. Install 1-3/4 diameter arm pin(s) and arm stop, Fig. 26a. Note: Arm stop will be required on the drive in side of the power unit side. Install at same time as arm pin, Fig. 26b. Notice the orientation of arm stop in Fig. 26c. Install Spring Pin to secure arm pin in place, Fig. 26a. After installing arms and pins, install arm Restraint Gears as follows: Install Restraint Gear onto arm clevis, as shown, Fig. 27a. Ensure side of gear marked TOP is facing upward, Fig. 27a. NOTE: TOP is stamped on top side of gear. You may need to pull up on the pin to allow enough room to install Restraint Gear. CAUTION Installation Pinch Point Keep Hands Above Groove Arms With 3 Holes In Bearing Bars: Then, install the (2) 3/8-16NC x 1-1/2 Lg. HHCS ((8) total for all (4) arms) into the gear and arm. Reference Fig. 25b and Fig. 28. Torque the Restraint Gear bolts to ft.-lbs. NOTE: To check operation of arm restraints, raise carriage 1 min. from full down position. Pull up on pin and adjust arms to desired position. To engage restraint, let pin-ring down allowing gear teeth to mesh together. It may be necessary to rotate arm slightly to engage gear teeth. NOTE: Pin, Spring, & Gear Block are all pre-assembled. Fig. 26b Fig. 26a 18 Arm Stop

19 Note: Location and Orientation of Arm Stop Fig. 26c Fig. 27b NOTE: Once arm is installed in yoke, pull up actuator pin and swing arm fully around, being sure that the Restraint Gear and Gear Block always stay aligned. If they do not stay aligned, remove restraint gear and install in the opposite position. TOP will be marked on top side of restraint gear NOTE beveled gear orientation Fig. 28 A A Fig. 27a Use holes marked A for Right Front and Left Rear. A A 19 Use holes marked A for Left Front and Right Rear.

20 20. Rubber Bumper Installation: Install rubber bumpers inside of both sides of lift using (2) M8 x 35mm socket bolts, Fig. 29. Fig. 29 NOTE: Figure shown with truck adapter accessory. M8 x 35mm Socket Bolt 21. Exterior Adapters: Install adapter bracket to outside of each column using (2) 5/16-18NC x 3/8 PHMS. Then, add adapters to the bracket as shown, Fig. 30. Fig. 30 5/16-18NC x 3/8 PHMS 20

21 22. Latch Cable Adjustment: A) Check to make sure the latch will properly engage and disengage. Slowly release the latch handle. A 1/8 gap between the top of the latch dog and the column is allowable, Fig. 31. B) When raising, listen to latches to be sure that both latch dogs fall into latch slots. If they do not, loosen clamp and adjust tension as necessary. C) Install left latch cover using 5/16-18NC x 3/8 lg PHMS. 1/8 Gap 25. Latch Release Decal: Install latch release decal on cover above latch release handle, Fig. 33. Raise Lift Off Latches Actuate To Release Latches NP266 Rev C CAUTION Pinch Point Raise Lift Off Latches Actuate To Release Latches NP266 Rev C Fig. 33 CAUTION Pinch Point Fig Pressure Test: Run lift to full rise and keep motor running for 5 seconds. Stop and check all hose connections. Tighten or reseal if required. Repeat air bleeding of cylinders. 24. Equalizer Cable Adjustment: Raise lift to check equalizer cable tension. Below carriage, grasp adjacent cables between thumb and forefinger, with about 15 lbs. effort you should just pull the cables together, Fig. 32. Adjust at upper tie-offs Fig. 18. Fig

22 NOTES 22

23 NOTES 23

24 Forward Lift 996 Industrial Drive Madison, IN Phone: Fax: Forward Lift; forward lift is a brand of RL Consolidated, A Dover Company. All rights reserved Unless otherwise indicated. Forward lift, RL Consolidated, Dover, and all other trademarks are property of Dover Corporation and its affilates.

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